US6315580B1 - PCB connector module for plug-in circuit breakers and fuses - Google Patents
PCB connector module for plug-in circuit breakers and fuses Download PDFInfo
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- US6315580B1 US6315580B1 US09/326,737 US32673799A US6315580B1 US 6315580 B1 US6315580 B1 US 6315580B1 US 32673799 A US32673799 A US 32673799A US 6315580 B1 US6315580 B1 US 6315580B1
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- passageways
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H73/00—Protective overload circuit-breaking switches in which excess current opens the contacts by automatic release of mechanical energy stored by previous operation of a hand reset mechanism
- H01H73/02—Details
- H01H73/06—Housings; Casings; Bases; Mountings
- H01H73/08—Plug-in housings
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02B—BOARDS, SUBSTATIONS OR SWITCHING ARRANGEMENTS FOR THE SUPPLY OR DISTRIBUTION OF ELECTRIC POWER
- H02B1/00—Frameworks, boards, panels, desks, casings; Details of substations or switching arrangements
- H02B1/015—Boards, panels, desks; Parts thereof or accessories therefor
- H02B1/04—Mounting thereon of switches or of other devices in general, the switch or device having, or being without, casing
- H02B1/056—Mounting on plugboards
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H71/00—Details of the protective switches or relays covered by groups H01H73/00 - H01H83/00
- H01H71/08—Terminals; Connections
- H01H2071/086—Low power connections for auxiliary switches, e.g. shunt trip
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
- H01R9/22—Bases, e.g. strip, block, panel
- H01R9/24—Terminal blocks
- H01R9/2425—Structural association with built-in components
Definitions
- the present invention relates generally to an electrical connector module for mounting a plurality of overcurrent protection devices, such as circuit breakers or fuses. More particularly, the present invention is directed to a connector module for mounting a plurality of plug-in circuit breakers, wherein the connector module contains female plugs for line and load male plugs, also known as positive and negative power terminals, along with female plugs for auxiliary alarm contact terminals.
- Fuses typically have a conductive wire element that rapidly heats and melts in response to an overcurrent condition, forming an open circuit. Fuses are often packaged in fuse modules containing additional circuit elements which transmit an alarm signal if the fuse opens in response to an overcurrent condition.
- Circuit breakers commonly comprise a movable electrical breaker contact and a stationary breaker contact. The movable electrical contact is typically coupled to an actuator mechanism that utilizes an electromagnetic device to open the breaker contacts when an over-current condition is detected.
- the actuator mechanism electrically couples the breaker contacts so that the circuit breaker is in a conducting, or on-state.
- the circuit breaker trips, and enters a non-conducting, or off-state.
- a handle on the external surface of the circuit breaker is commonly coupled to the actuator mechanism.
- the actuator-handle provides a visual indication of the state of the circuit breaker (e.g., on, tripped, and off) while also permitting the user to reset the circuit breaker after the circuit breaker has been tripped or to deliberately turn the circuit breaker off during routine repair or maintenance.
- Some circuit breakers include an additional alarm circuit, which sends an alarm signal to other circuits when the alarm circuit senses that the circuit breaker has been tripped.
- FIG. 1 shows a perspective view of a prior art circuit breaker module 100 used in a power distribution module.
- a plurality of circuit breakers 110 , 120 , 130 are coupled by frictional forces or by mechanical connectors to base 180 and front face plate 122 .
- Each circuit breaker 110 , 120 , 130 has a corresponding actuator handle 105 .
- screw connectors 131 are commonly used to electrically couple circuit breakers 110 , 120 , 130 to busbars 162 , 164 and connectors 160 , 161 , 151 to couple current to a rear connector 134 on panel 124 .
- Bus bars 162 , 164 couple a negative polarity power terminal, often called a line terminal, of each circuit breaker 110 , 120 , 130 to a negative power terminal.
- Connectors 160 , 161 , 151 separately couple the load terminal, often called the positive power terminal, of each circuit breaker 110 , 120 , 130 to separate electronic loads.
- circuit breaker module 100 provides the benefit of several circuit breakers 110 , 120 , 130 arranged to control the current or power in different portions of a power distribution module, it has several drawbacks.
- One drawback is that it may be inconvenient to replace one of the circuit breakers 110 , 120 , 130 . Replacement of circuit breakers may be required if a circuit breaker is damaged. Additionally, circuit breakers may need to be replaced if it is determined that a different response is required by the circuit breaker. For example, the user may determine that a higher amperage circuit breaker is required for a particular application.
- the time to replace a circuit breaker 110 , 120 , 130 in module 100 may be significant because the total time to replace a circuit breaker includes the time to: 1) withdraw the module; 2) remove any exterior housing elements surrounding the screw connectors 131 ; 3) disconnect the screw connectors 131 ; 4) extract the old circuit breaker; 5) insert a new circuit breaker; 6) connect screw connectors 131 to the new circuit breaker; 7) attach any exterior housing elements; and 8) re-insert module 100 .
- circuit breaker module 100 Another drawback with circuit breaker module 100 is that the housing and connector are comparatively bulky. There is a general trend to miniaturize all aspects of power supply and power distribution systems. Unfortunately, the total volume of circuit breaker module 100 , including connectors 131 ; busbars 162 , 164 ; and connectors 160 , 161 , 151 is significant.
- Circuit breakers with alarm circuits typically have additional auxiliary terminals for sending an alarm signal that is indicative of the operating state of the circuit breaker.
- an alarm circuit preferably sends a logical “high” signal from an alarm terminal to indicate that the circuit breaker has been tripped due to an overcurrent event.
- the alarm signal may, for example, be used to trigger an indicator light to alert the user that a circuit breaker has been tripped.
- Circuit breakers have two alarm contact terminals. More commonly, however, circuit breakers have three alarm contact terminals corresponding to normal-off, normal-closed, and common terminals. An electrical connection must be provided to each alarm contact terminal of each circuit breaker of a circuit breaker module. Unfortunately, this increases the complexity of the electrical connection required in a circuit breaker module.
- FIG. 2 is a prior art side-view drawing of a circuit breaker 210 with an alarm circuit 220 providing an alarm signal via stab-type alarm terminal 216 .
- Line contact 212 and load contact 214 also comprise stab-type connectors.
- Stab-type connectors are a type of connector that has a comparatively thin, blade-like connector surface which is pressed into a female connector slot or socket “(i.e., stabbed)” to form a tight mechanical and electrical coupling.
- Stab-type connectors have the advantage that the small surface area of a male stab-type connector permits a significant penetration pressure to be applied in inserting the male connector.
- stab-type connectors have the disadvantage of having a comparatively small cross-sectional area for current to flow.
- FIG. 3A is a perspective view of a prior art circuit breaker module 254 designed to be loaded with a plurality of circuit breakers 210 having stab-type line and load terminal connectors 212 , 214 (not shown) and stab-type alarm contact terminal connectors 216 (not shown) as illustrated on the circuit breaker 210 of FIG. 2 .
- three circuit breakers 210 are shown installed in a module 254 designed to hold a total of four circuit breakers.
- a busbar 288 is used to provide an electrical connection to line contacts 212 .
- Contacts 256 are spring-biased receptacles configured to contact load contacts 214 . Additional connector legs 282 facilitate installation of module 254 as an integral unit.
- FIG. 3B is a top view of module 254 with circuit breaker 210 removed, to more clearly show the electrical connectors.
- Each aperture 260 allows passage of a line contact 212 (not shown) in order to receive power from a power source spring biased alarm contacts 262 are dimensioned to mate with corresponding alarm terminals 216 (not shown).
- the alarm contacts 262 are electrically connected to each other by alarm contact line 264 to respective circuit breakers 210 .
- Load connectors 258 provide a bolt and screw connection site to secure external electrical lines.
- circuit breaker module 254 provides several benefits, it has several drawbacks.
- One drawback of stab-type connectors is that they have a limited structural strength, i.e., the comparatively small cross-sectional area of each stab-type terminal 212 , 214 provides only limited resistance to transverse and rotational forces.
- circuit breaker 210 is mounted to a socket perpendicular to a vertical surface, the force of gravity will generate transverse and rotational forces acting to dislodge the stab-type connectors. This may necessitate the use of long stab-connectors with a high contact pressure, which increases the difficulty of inserting or removing a circuit breaker.
- circuit breaker connector module 254 does not address the need for reducing the cost per electrical connection.
- the cost of circuit breakers like other electronic components, continues to decrease over time. It is desirable that the cost of the connector module divided by the number of circuit breakers decreases as the connector module is increased in size to accommodate a larger number of circuit breakers. This is commonly known as “increasing returns to scale.”
- Stab connector receptacles 256 , 262 will tend to have a substantially constant price per female receptacle, assuming that they are purchased from a commercial vendor in large production lots.
- circuit breaker module 254 requires a substantial support structure including connector legs 282 and support surfaces 284 to facilitate removing or installing module 254 as an assembled unit into an electrical system.
- the material cost of the support structure will tend to increase as the module 254 is increased in size to connect additional circuit breakers. Consequently, it can be expected that there will be no significant cost reduction to increasing the size of module 254 to accommodate additional circuit breakers.
- compact plug-in circuit breakers 400 commonly have power connections comprised of male plug-shaped connectors 410 .
- plug-in circuit breakers commonly include additional alarm contact terminal connectors 420 for transmitting an alarm signal.
- the alarm contact terminals may be any style of male plug, but are typically in the form of pins, prongs, or blades with planar surfaces.
- plug-in circuit breakers 400 It is desirable in many applications, such as telecommunication applications, to utilize a large number (e.g., ten to twenty) of plug-in circuit breakers 400 as part of a power distribution system.
- a large number e.g., ten to twenty
- separate wire connections are soldered to each of the alarm contact terminals 420 after the male plugs are plugged into two female socket receptacles.
- the male plugs 410 of plug-in circuit breaker 400 preferably fit into female sockets (not shown in FIG. 4) with a friction fit so that the male plugs may be inserted or withdrawn in order to insert or remove the circuit breaker.
- this permits what is commonly known as “plug and play” operation, since both mechanical and electrical connection to the circuit breaker is made by inserting the plugs 410 into their sockets.
- the compact male alarm contact terminals 420 also require a reliable electrical connection in order to provide reliable alarm signals.
- planar alarm contacts 420 compared with male plugs 410 make it difficult to design a low-cost connector socket that simultaneously mates with an appropriate friction fit to both types of male plugs 410 and auxiliary contact terminals 420 .
- the two different styles of male terminal connectors 410 , 420 makes it difficult to achieve a friction fit with the appropriate connection length and pressure for both types of male connectors 410 , 420 in a low-cost structure with reasonable fabrication tolerances.
- This problem is exacerbated in the context of circuit breaker modules in which the circuit breakers are mounted with the axis of the male connectors disposed perpendicular to the force of gravity, i.e., with the force of gravity acting to torque the male connectors.
- One potential solution to this problem is to use additional clamps or screws to apply a pressure between the male connectors and sockets. Clamps and screws are commonly used in some types of electrical connectors to facilitate the mating of different types of male connectors to a common female connector.
- additional clamps or screws increase the cost of the connector and also require the user to spend additional time to adjust the clamp or screws in order to remove or install the male connector.
- clamps and screws are inconsistent with “plug and play” operation.
- What is desired is a connector module for a plurality of overcurrent protection devices in which all of the male connectors of each overcurrent protection devices are demountably mounted to the female sockets of the connector module by friction coupling.
- the present invention is directed towards a connector module for providing what is called “plug and play” electrical connections to a plurality of overcurrent protection devices in which the electrical connections to each overcurrent protection device are automatically made by inserting the overcurrent protection device into the connector module.
- the present invention generally comprises a connector module for mechanically mounting and providing electrical connections to a plurality of overcurrent protection devices each having first and second male electrical plugs, including: a mounting substrate having a first side and a second opposed side; first and second plug passageways disposed in said substrate for each overcurrent protection device, the plug passageways shaped and spaced apart from each other to permit the passage of the two male plugs of each overcurrent protection device through the passageways in the direction from the first side to the second side; a conductive load busbar member for each of the first plug passageways, each of the conductive members mounted by a mechanical connector to the second side of said substrate and having a socket shaped and positioned to mate with a friction fit with a corresponding male plug extending through the first connector passageway; and a
- a preferred embodiment of the connector module of the present invention is directed towards providing plug and play electrical connections to a plurality of circuit breakers, wherein each circuit breaker has both plug current connectors and auxiliary signal terminals.
- the mounting substrate is a printed circuit board and further comprises auxiliary signal terminal passageways and clips mounted to the second side of the substrate to provide an electrical connection to the auxiliary signal terminals.
- One object of the present invention is a low-cost connector module adapted for plug-in circuit breakers with crown-style male plugs.
- the sockets comprise protruded holes dimensioned to mate with crown-style male plugs.
- Another object of the present invention is a low cost clip connector for making contact to auxiliary signal terminals.
- each clip is sized, shaped, and positioned to grasp a single auxiliary terminal whereas electrical connections to each clip are made by tracks on the substrate.
- Still another object of the present invention is a low cost manufacturing method to fabricate the connector module.
- FIG. 1 is a perspective view of a prior art circuit breaker module.
- FIG. 2 is a side view of a prior art circuit breaker including an alarm circuit and stab-type current and alarm terminals.
- FIG. 3A is a perspective view of a prior art circuit breaker module for mounting a plurality of circuit breakers with stab-type terminals.
- FIG. 3B is a top view of the female connector surface of the circuit breaker module of FIG. 3A with the circuit breakers removed.
- FIG. 4 is a perspective view of a prior art plug-in circuit breaker with plug-type male current connector terminals and plate-type alarm contact terminals.
- FIG. 5 is a front perspective view of the circuit breaker module of the present invention.
- FIG. 6 is a rear perspective view of the circuit breaker module of the present invention.
- FIG. 7A shows a rear view of two circuit breaker modules of the present invention linked together in a housing.
- FIG. 7B is a front view of the housing of FIG. 7 A.
- FIG. 8 is rear view of the circuit breaker module of FIG. 5 .
- FIG. 9 is a cross-sectional view of the circuit breaker module of FIG. 8 along line 9 — 9 .
- FIG. 10 is a cross-sectional view of the circuit breaker module of FIG. 8 along line 10 — 10 .
- FIG. 11 is a cross-sectional view of the circuit breaker module of FIG. 8 long line 11 — 11 .
- FIG. 12 is a perspective view of a conductive busbar member of the resent invention.
- FIG. 13 is a top view of the busbar of FIG. 12 .
- FIG. 14 is a cross-sectional view of the busbar of FIG. 13 along line 14 — 14 .
- FIG. 15 is a side view of a conductive busbar member of the present invention.
- FIG. 16 is a perspective view of a preferred embodiment of a conductive clip.
- FIG. 17 ( a ) shows a top view of the conductive clip of FIG. 16 .
- FIG. 17 ( b ) shows a front view of the conductive clip of FIG. 16 .
- FIG. 17 ( c ) shows a side view of the conductive clip of FIG. 16 .
- FIG. 18 is a rear view of the circuit breaker module of FIG. 6 showing in more detail conductive traces linking rows of conductive clips.
- FIG. 19 is a detailed portion of the cross-section of FIG. 10 .
- FIG. 20 is a front view of a clip attached to a substrate showing an installed auxiliary signal terminal in phantom.
- FIG. 21 is a cross section similar to FIG. 10 but showing a circuit breaker module adapted for circuit breakers having crown-style male plugs.
- FIG. 22 is detailed portion of FIG. 21 showing in more detail a region around one plug and one alarm contact terminal of a circuit breaker about to be inserted into the circuit breaker module.
- the present invention generally comprises a connector module for overcurrent protection devices wherein each overcurrent protection device has male current plug connectors and male auxiliary signal terminals.
- One potential application for the inventive connector module includes its use as a connector module for fuse modules with auxiliary alarm signal terminals.
- Another potential application for the inventive connector module is for use with circuit breakers having auxiliary terminals used to perform a control function, such as circuit breakers with auxiliary terminals used to receive remote control signals (e.g., signals to reset or turn-off the circuit breaker).
- a preferred use for the connector module of the present invention is as a connector module for a plurality of plug-in circuit breakers having plug-type male current connectors and auxiliary male alarm contact terminals.
- the connector module of the present invention is shown and described in detail as being used with plug-in circuit breakers having alarm contact terminals, it will be understood that the connector module of the present invention includes applications as a connector module for a variety of overcurrent protection devices and that plug-in circuit breakers are merely exemplary devices.
- FIG. 5 is a front perspective view of the circuit breaker module 500 of the present invention showing one installed circuit breaker 400 .
- Module 500 comprises a mounting substrate 510 , which is preferably a printed circuit board substrate, patterned with two spaced apart male plug passageways 520 , 525 and signal terminal passageways 530 for each circuit breaker 400 .
- the passageways 520 , 525 , 530 may be fabricated using any conventional printed circuit board fabrication process.
- Modern printed circuit board fabrication processes permit extremely accurate selection of the location, diameter, and spacing of passageways 520 , 525 , 530 .
- Plug passageways 520 , 525 and signal terminal passageways 530 are shaped, dimensioned, and spaced apart so that corresponding male plug connectors 410 and auxiliary signal terminals 420 (shown in FIG. 4) may be inserted into the passageways 520 , 525 , 530 .
- Passageways 520 , 525 are preferably at least one-tenth of an inch larger in diameter than plugs 410 , since this enables the passageways to assist to in aligning the plugs, i.e., the slightly larger diameter of the passageways 520 , 525 compared with the plugs and sockets 570 (not shown in FIG. 5) assists the user aligning plugs 410 to the sockets 570 (shown in FIG.
- diameter of passageways 520 , 525 to be several tenths (e.g., two or three) of an inch larger in diameter than plugs 410 provides an alignment benefit.
- Module 500 has one conductive (load) busbar member 540 to couple load current from each circuit breaker 400 .
- a conductive support 550 is configured to provide a common conductive (line) busbar member linking one terminal of each installed circuit breaker 400 to a common line current connection.
- Support 550 is a preferred design because support 550 may be used to mechanically couple module 500 to a housing (not shown in FIG. 5 ). However, the electrical function of support 550 could also be accomplished using a plurality of individual conductive busbar members (e.g., members similar to member 540 ) each individually coupled to a common line connection site.
- support 550 may be desirable to replace support 550 with a plurality of individual conductive busbar members (similar to member 540 ) which are not electrically coupled to each other. This may be useful, for example, in an application for which the circuit breakers are connected to different voltage sources so that both line and load power connections to the two plugs 410 of each circuit breaker are completely independent of each other.
- Support 550 and members 510 are mechanically coupled to substrate 510 by mechanical connectors 560 .
- Mechanical connectors 560 are preferably rivets, but may comprise any mechanical coupling device or fastener (e.g., epoxy) consistent with attaching support 550 and members 540 to substrate 510 .
- Bolt hole connectors 590 permit support 550 to be bolted to a housing (not shown in FIG. 5) or attached to other elements.
- substrate 510 has a first side 514 and second side 512 .
- First side 514 is preferably a bare insulating surface, i.e., has no conductive metal in regions adjacent circuit breakers 400 to prevent deleterious shorting of circuit breaker contact terminals 410 , 420 .
- FIG. 6 is a rear perspective view of module 500 .
- Conductive clips 600 are disposed adjacent signal terminal passageways 530 above second surface 512 of substrate 510 .
- Members 540 and support 550 have sockets 570 , 575 dimensioned to mate with the plug terminals 410 of a plug-in circuit breaker 400 extending through plug passageways 520 , 525 .
- FIG. 6 shows, at far right, a plug terminal 410 of one installed circuit breaker extending through a socket 570 in a member 540 .
- members 540 are spaced apart from one another, i.e., do not touch one another.
- Members 540 are preferably in the shape of L-shaped members with a portion of the L-shaped member extending perpendicular from second surface 512 of substrate 510 .
- Second surface 512 of substrate 510 is preferably a bare (insulating) surface adjacent each member 540 so that the members are electrically isolated from one another and from support 550 .
- electrical traces sometimes known as “tracks” are preferably disposed on second surface 512 adjacent to, and electrical coupled to, clips 600 in order to provide transmission paths (not shown in FIG. 6) for alarm signals from clips 600 to a signal receiving portion (not shown in FIG. 6) of substrate 510 .
- FIG. 5 a preferred design is for a module 500 designed to accept twelve plug-in circuit breakers 400 . Limiting the number of circuit breakers 400 that module 500 accepts reduces the weight and stress upon substrate 500 . This is desirable in order to increase the reliability of module 500 , i.e., to prevent substrate 510 from cracking or warping during extended use. However, a module for mounting a larger number of circuit breakers may be achieved by mechanically coupling a plurality of individual modules 500 together.
- FIG. 7A is a rear perspective view of two circuit breaker modules 500 -A, 500 -B coupled by a plate 750 and bolts 760 to form a combined circuit breaker module 700 .
- FIG. 7B is a front view of the housing of FIG. 7 A. As shown in FIG. 7B, preferably additional housing segments 730 , 740 and a front plate 720 coupled by screws 710 are used to house and support the combined module 700 .
- FIG. 12 is a detailed perspective view of member 540 .
- Socket 570 may comprise any style of electrical socket shaped to mate with a friction fit to a plug 410 . This includes sockets with detents and other conventional mating surfaces shaped to mate with a male connector.
- plug in circuit breakers 400 are commonly sold with crown-style plugs 410 that are shaped to mate with a cylindrical hole of a predetermined length at what is commonly known as a connector “crown.” Consequently, in a preferred embodiment socket 570 is substantially cylindrical in shape and with a diameter and length determined by the specific requirements of a crown-style plug 410 .
- a crown-style plug 410 for common miniature plug-in circuit breakers requires a minimum socket length in order to achieve a proper mating of about 0.25 inches.
- a protruded socket design in which the average copper thickness is about one-eighth of an inch but which the protrusion has a cylindrical length of about one-quarter of an inch results in a substantial cost reduction
- the member 540 shown in FIG. 12 is preferably formed with a protruded socket 570 , since this results in about a factor of 3.5 lower manufacturing costs compared with manufacturing member 540 with a uniform thickness of copper and forming a cylindrical socket 570 by a drilling or reaming process.
- the protruded hole and all the cutting used to form member 540 are preferably performed on a dedicated progressive punch and die set.
- the ninety degree bend 1230 used to form the “L”-shape of members 540 is preferably made on a break press.
- Rivet holes 1210 , 1220 permit member 540 to be riveted to substrate 510 .
- FIG. 13 is a head-on view of member 540 showing preferred dimensions, in inches, for common plug-in circuit breakers.
- FIG. 14 is a cross-sectional view of socket 570 along line 14 — 14 of FIG. 13, showing preferred dimensions in inches.
- FIG. 15 is a side view of member 540 showing preferred dimensions in inches.
- Clips 600 may be any type of clip which may be mounted on a mounting substrate (e.g., a printed circuit board) to form a female connector for auxiliary signal terminals and which has at least one contact region that supplies a sufficient pressure to maintain a reliable electrical connection to auxiliary signal terminals.
- a clip is commonly defined as a pinch-type connector in which a spring element acts to apply pressure to jaw or finger elements to form an electrical contact.
- clips 600 may alternately be described as a connector, or a socket connector, which includes spring contact elements.
- clip describes the grasping function of clips 600 while avoiding potential confusion with the connector module 500 and with the male plug sockets 570 .
- Each individual clip 600 is preferably designed to minimize manufacturing costs. Studies by the inventors indicated that a plurality of clips 600 coupled by the conductive tracks of a printed circuit board results in over a five-fold reduction in cost of clip 600 compared with designing a large area connector socket to mate with the auxiliary contact terminals 420 of a large number of circuit breakers 400 . In many applications it is desirable that each clip 600 has a contact pressure in the range of about 100 grams. A preferred clip design which achieves a contact pressure of about 100 grams is shown in FIGS. 16-17. As shown in the perspective view of FIG. 16, each clip 600 preferably has two finger segments 1610 , 1620 dimensioned to mate with the surface of alarm contact terminals 420 with a significant contact pressure, e.g., about 100 grams.
- FIG. 17 ( a ) shows a top view of clip 600 showing preferred dimensions in inches.
- FIG. 17 ( b ) shows a front view of clip 600 showing preferred dimensions in inches.
- FIG. 17 ( c ) shows a side view of clip 600 showing preferred dimensions in inches.
- FIG. 18 is a rear view of module 500 showing clips 600 installed on the second surface 512 of substrate 510 .
- Clips 600 are preferably soldered to conductive traces (also commonly known as “tracks”) 1810 disposed on second surface 512 .
- Traces 1810 may be formed by any conventional printed circuit board fabrication process. Traces 1810 are shown as electrically coupling rows of clip terminals together in a parallel arrangement (i.e., common terminals of each circuit breaker coupled together; normal-on signal terminals of each circuit breaker coupled together; and normal-off signal terminals of each circuit breaker coupled together). However, more generally traces 1810 may be configured to couple alarm signals from clips 600 in other ways, such as permitting an individual electrical connection to be made to each clip 600 .
- FIG. 19 is detailed view of a portion of FIG. 10 .
- plugs 410 extend through plug passageways 1910 in substrate 510 and mate with sockets 570 in member 540 and support 550 .
- Sockets 570 are preferably protruded holes shaped to provide a friction fit with plugs 410 .
- the diameter and length of the protruded holes forming sockets 570 may be selected to obviate the need for additional mating surfaces. Generally, selecting the diameter of the sockets 570 to be only slightly larger than that of the plugs 410 facilitates forming a reliable mechanical and electrical connection.
- the length of the protruded hole is another consideration. For circuit breakers 400 with crown-style plugs 410 , the length of the protruded holes should be selected to mate with the crown of the plug.
- auxiliary alarm contact terminals 420 extend through signal terminal passageways 1920 .
- Alarm contact terminals 420 are grasped by fingers 1610 , 1620 (finger 1610 shown in phantom) of clip 600 proximate a distal end of each alarm contact terminal 420 .
- FIG. 20 which shows a front view of a clip 600 and an inserted alarm contact terminal 420 shown in phantom, it can be seen that the alarm contact terminal will make contact with fingers even though it may be displaced up or down by a distance ⁇ /2.
- Finger contacts 1610 , 1620 are also insensitive to small lateral displacements of alarm contact terminal 420 in passageway 1920 .
- finger contacts 1610 , 1620 of each clip will automatically grasp alarm contacts 420 in spite of small vertical and lateral displacements of alarm contact terminals 420 caused by manufacturing tolerance of plugs 410 and sockets 570 .
- finger contacts 1610 , 1620 are insensitive to small angular shifts caused by a slight (e.g., one degree) tilt of circuit breaker 400 caused by the force of gravity (shown in FIG. 19 by arrow 1990 ) producing a torque on the installed circuit breaker.
- the present invention permits what is called “plug and play” installation or replacement of a circuit breaker. No additional clamps or bolts are required to install the circuit breaker.
- the sockets 570 may be dimensioned to permit installation or removal of the circuit breaker with a reasonable force, i.e., consistent with the hand strength of the average user and without overstressing substrate 510 .
- FIG. 21 shows a cross-sectional view, similar to that of FIG. 19, for a circuit breaker 400 having crown-style plugs 410 , showing preferred dimensions in inches.
- Each crown-style plug has a metallic crown terminal section 2110 , typically comprised of a layer of plated gold.
- each plug In order to ensure a reliable electrical connection, each plug must be inserted into a cylindrical socket 570 beyond the center of the crown terminal (shown in phantom as line 2120 ). For one common style of crown-style plug, this distance, as measured from the base 2130 of the plug corresponds to a distance of 0.24 inches, as shown in FIG. 21 . As can be seen in FIG.
- FIG. 22 is a detailed view of a portion of FIG. 21 .
- plug passageway 1910 is slightly larger in diameter than cylindrical socket 570 , which facilitates mating.
- alarm contact signal terminals 420 have a width less than that of passageways 1920 in order to facilitate their insertion.
- the connector module of the present invention may also be used with electronic devices which do not have auxiliary terminals, such as conventional plug-in fuses and circuit breakers without alarm terminals.
- sockets 570 may be shaped to mate with a variety of different shaped male connectors.
- clips 600 are shown as being designed to mate with alarm contact terminals 420 having planar surfaces, more generally any male/female clip mating configuration may be used to accommodate changes in the shape of alarm contact terminals 420 .
- circuit breakers 400 are currently commonly sold with male alarm contact terminals 420
- plug-in circuit breakers 400 with female alarm contact terminals 420 although less desirable, are technically possible.
- Connector module 500 may be adapted for use with plug-in circuit breakers 400 having female alarm contact terminals 420 by replacing clip 600 with any conventional male clip or socket which may be mounted to a mounting substrate to form a male/female connection with female alarm contact terminals.
- the present invention comprises a connector module for over-current protection devices.
- the connector module addresses the need for a low-cost plug and play connector module for plug-in circuit breakers having male line and load current plugs and additional auxiliary signal terminals.
- the use of a printed circuit board as a support substrate for busbars and alarm contact clips results in a low manufacturing cost.
- load busbar members are formed from copper strips with protruded sockets and riveted onto the substrate.
- a common (line) busbar forms a support member and is also riveted to the substrate.
- Contacts to auxiliary alarm contact terminals are made using a plurality of clips mounted to the substrate, wherein tracks on the printed circuit board substrate are used to make electrical contact to the clips.
Abstract
Description
Claims (15)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/326,737 US6315580B1 (en) | 1999-06-04 | 1999-06-04 | PCB connector module for plug-in circuit breakers and fuses |
US09/585,265 US6530811B1 (en) | 1999-06-04 | 2000-06-02 | Modular distribution assembly |
US09/585,909 US6560123B1 (en) | 1999-06-04 | 2000-06-02 | Plug-in GMT fuse block |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/326,737 US6315580B1 (en) | 1999-06-04 | 1999-06-04 | PCB connector module for plug-in circuit breakers and fuses |
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US09/585,265 Continuation-In-Part US6530811B1 (en) | 1999-06-04 | 2000-06-02 | Modular distribution assembly |
US09/585,909 Continuation-In-Part US6560123B1 (en) | 1999-06-04 | 2000-06-02 | Plug-in GMT fuse block |
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US6315580B1 true US6315580B1 (en) | 2001-11-13 |
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US09/326,737 Expired - Fee Related US6315580B1 (en) | 1999-06-04 | 1999-06-04 | PCB connector module for plug-in circuit breakers and fuses |
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US6456485B1 (en) * | 2001-08-27 | 2002-09-24 | Eldre Corporation | Device for connecting a circuit breaker to a bus bar |
US20030067756A1 (en) * | 2001-09-21 | 2003-04-10 | Popa Heinz Erich | Electrical service distribution board |
US6617708B2 (en) * | 2001-09-18 | 2003-09-09 | C&D Charter Holdings, Inc. | Modular power distribution system |
US6667876B1 (en) | 2002-07-26 | 2003-12-23 | Harry B. Neeff | Wiring track having an internal wiring cavity and providing for the mounting of a din rail thereon |
US20040113748A1 (en) * | 2003-08-28 | 2004-06-17 | Emerson Electric Co. | Apparatus adapted to be releasably connectable to the sub base of a thermostat |
US6784783B2 (en) * | 2000-10-24 | 2004-08-31 | Cooper Technologies Company | Compact fused disconnect switch |
US6821152B2 (en) * | 2001-04-12 | 2004-11-23 | Marconi Communications, Inc. | Power entry panel with input terminal block having direct connection |
US20050087433A1 (en) * | 2003-10-23 | 2005-04-28 | Ta-Jung Yang | Breaker distribution module |
US6905372B2 (en) * | 2001-10-03 | 2005-06-14 | Adc Telecommunications, Inc. | Internal power bus and power output assembly |
US20070035914A1 (en) * | 2004-05-24 | 2007-02-15 | Ellenberger & Poensgen Gmbh | Modular current distributor for high currents |
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US20080062621A1 (en) * | 2000-04-03 | 2008-03-13 | Adc Telecommunications, Inc. | Power distribution panel with modular elements |
US20080105476A1 (en) * | 2006-11-06 | 2008-05-08 | Korich Mark D | Power inverter connector having integrated current sensors |
US7581965B1 (en) | 2008-05-01 | 2009-09-01 | Commscope, Inc. Of North Carolina | Bottom entry interconnection element for connecting components to a circuit board |
USRE41662E1 (en) * | 2001-10-03 | 2010-09-14 | Adc Telecommunications, Inc. | Input power connector for distribution panel |
US20110028031A1 (en) * | 2009-07-29 | 2011-02-03 | Abb Technology Ag | Modular test plug |
US7957121B1 (en) | 2006-08-18 | 2011-06-07 | Nichols Mitchell A | Circuit breakers and circuit breaker box |
JP2011142800A (en) * | 2009-12-11 | 2011-07-21 | Tempearl Industrial Co Ltd | Structure for measuring voltage to be supplied to load circuit of home distribution board |
US20110235244A1 (en) * | 2010-03-29 | 2011-09-29 | Mills Patrick W | Plug-in circuit breaker assembly |
US20120050955A1 (en) * | 2010-08-30 | 2012-03-01 | Siemens Aktiengesellschaft | Power switch receiving module |
US20130149879A1 (en) * | 2011-12-12 | 2013-06-13 | Tyco Electronics Japan G.K. | Connector |
CN103208751A (en) * | 2013-04-15 | 2013-07-17 | 南京国电南自电网自动化有限公司 | Secondary apparatus for installation, wiring and operation in front of board |
US20130215581A1 (en) * | 2012-01-27 | 2013-08-22 | Chatsworth Products, Inc. | Board-mounted circuit breakers for electronic equipment enclosures |
US8649160B2 (en) | 2012-02-07 | 2014-02-11 | Eaton Corporation | Plug-in circuit breaker assembly including insulative retainers |
US8848346B2 (en) | 2010-09-28 | 2014-09-30 | Adc Telecommunications, Inc. | Power distribution panel with modular circuit protection elements |
US20150061568A1 (en) * | 2013-08-27 | 2015-03-05 | Armando Martinez | Portable Solar-Powered Generator |
US20150137915A1 (en) * | 2013-11-21 | 2015-05-21 | Labinal, Llc | Circuit breaker assembly including a plurality of controllable circuit breakers for local and/or remote control |
CN105633664A (en) * | 2014-11-04 | 2016-06-01 | 安徽美琳电子有限公司 | Power strip reliable in connection |
US9460881B1 (en) * | 2015-04-30 | 2016-10-04 | Eaton Corporation | Compact plug and socket unit isolator systems for motor control centers (MCC) and related MCC cabinets |
US9509086B2 (en) | 2012-01-27 | 2016-11-29 | Chatsworth Products, Inc. | Cable retention system for power distribution unit |
US9531126B2 (en) | 2014-06-05 | 2016-12-27 | Chatsworth Products, Inc. | Electrical receptacle with locking feature |
US20170005458A1 (en) * | 2014-01-03 | 2017-01-05 | Electronic Theatre Controls Inc. | Electrical circuit breaker assembly |
US9984845B2 (en) * | 2016-05-11 | 2018-05-29 | Safran Electrical & Power | Circuit breaker with interference fit socket |
US10102994B2 (en) | 2016-04-19 | 2018-10-16 | Safran Electrical & Power | Integral contact socket for plug-in circuit breakers |
US20180375263A1 (en) * | 2017-06-21 | 2018-12-27 | Foxconn Interconnect Technology Limited | Electrical connector |
US10547145B2 (en) | 2018-02-05 | 2020-01-28 | Chatworth Products, Inc. | Electric receptacle with locking feature |
US10707040B2 (en) | 2017-05-25 | 2020-07-07 | Ge Aviation Systems Limited | Power distribution system with snubber plate |
CN112219457A (en) * | 2018-04-25 | 2021-01-12 | 西门子股份公司 | Establishment of an electrical connection between a component and a contact plate |
EP3879947A1 (en) * | 2020-03-13 | 2021-09-15 | GE Aviation Systems Limited | A power distribution assembly |
EP4071948A4 (en) * | 2019-12-25 | 2023-03-08 | Huawei Digital Power Technologies Co., Ltd. | Power distribution module and communication power supply system |
US11923677B2 (en) | 2021-01-14 | 2024-03-05 | II Joseph M. DeLapa | Customizable overcurrent protection assistant |
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US20080062621A1 (en) * | 2000-04-03 | 2008-03-13 | Adc Telecommunications, Inc. | Power distribution panel with modular elements |
US7460360B2 (en) * | 2000-04-03 | 2008-12-02 | Adc Telecommunications, Inc. | Power distribution panel with modular elements |
US6784783B2 (en) * | 2000-10-24 | 2004-08-31 | Cooper Technologies Company | Compact fused disconnect switch |
US6821152B2 (en) * | 2001-04-12 | 2004-11-23 | Marconi Communications, Inc. | Power entry panel with input terminal block having direct connection |
US6456485B1 (en) * | 2001-08-27 | 2002-09-24 | Eldre Corporation | Device for connecting a circuit breaker to a bus bar |
US6617708B2 (en) * | 2001-09-18 | 2003-09-09 | C&D Charter Holdings, Inc. | Modular power distribution system |
US20030067756A1 (en) * | 2001-09-21 | 2003-04-10 | Popa Heinz Erich | Electrical service distribution board |
US6905372B2 (en) * | 2001-10-03 | 2005-06-14 | Adc Telecommunications, Inc. | Internal power bus and power output assembly |
US7458860B2 (en) | 2001-10-03 | 2008-12-02 | Adc Telecommunications, Inc. | Internal power bus and power output assembly |
US20050170701A1 (en) * | 2001-10-03 | 2005-08-04 | Adc Telecommunications, Inc | Internal power bus and power output assembly |
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USRE41662E1 (en) * | 2001-10-03 | 2010-09-14 | Adc Telecommunications, Inc. | Input power connector for distribution panel |
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JP2011142800A (en) * | 2009-12-11 | 2011-07-21 | Tempearl Industrial Co Ltd | Structure for measuring voltage to be supplied to load circuit of home distribution board |
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US8094436B2 (en) * | 2010-03-29 | 2012-01-10 | Eaton Corporation | Plug-in circuit breaker assembly |
US20110235244A1 (en) * | 2010-03-29 | 2011-09-29 | Mills Patrick W | Plug-in circuit breaker assembly |
US20120050955A1 (en) * | 2010-08-30 | 2012-03-01 | Siemens Aktiengesellschaft | Power switch receiving module |
US8913372B2 (en) * | 2010-08-30 | 2014-12-16 | Siemens Aktiengesellschaft | Power switch receiving module |
US8848346B2 (en) | 2010-09-28 | 2014-09-30 | Adc Telecommunications, Inc. | Power distribution panel with modular circuit protection elements |
US10193314B2 (en) | 2010-09-28 | 2019-01-29 | Commscope Technologies Llc | Power distribution panel with modular circuit protection elements |
US9054450B2 (en) * | 2011-12-12 | 2015-06-09 | Tyco Electronics Japan G.K. | Connector |
US20130149879A1 (en) * | 2011-12-12 | 2013-06-13 | Tyco Electronics Japan G.K. | Connector |
US9509086B2 (en) | 2012-01-27 | 2016-11-29 | Chatsworth Products, Inc. | Cable retention system for power distribution unit |
US10374360B2 (en) | 2012-01-27 | 2019-08-06 | Chatsworth Products, Inc. | Cable retention system for power distribution unit |
US10187995B2 (en) | 2012-01-27 | 2019-01-22 | Chatsworth Products, Inc. | Board-mounted circuit breakers for electronic equipment enclosures |
US20130215581A1 (en) * | 2012-01-27 | 2013-08-22 | Chatsworth Products, Inc. | Board-mounted circuit breakers for electronic equipment enclosures |
US9844143B2 (en) | 2012-01-27 | 2017-12-12 | Chatsworth Products, Inc. | Board-mounted circuit breakers for electronic equipment enclosures |
US10349524B2 (en) | 2012-01-27 | 2019-07-09 | Chatsworth Products, Inc. | Board-mounted circuit breakers for electronic equipment enclosures |
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US10594082B2 (en) | 2012-01-27 | 2020-03-17 | Chatsworth Products, Inc. | Cable retention system for power distribution unit |
US8649160B2 (en) | 2012-02-07 | 2014-02-11 | Eaton Corporation | Plug-in circuit breaker assembly including insulative retainers |
US9197040B2 (en) | 2012-02-07 | 2015-11-24 | Labinal, Llc | Plug-in circuit breaker assembly including insulative retainers |
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US20150061568A1 (en) * | 2013-08-27 | 2015-03-05 | Armando Martinez | Portable Solar-Powered Generator |
US9460879B2 (en) * | 2013-11-21 | 2016-10-04 | Labinal, Llc | Circuit breaker assembly including a plurality of controllable circuit breakers for local and/or remote control |
US20150137915A1 (en) * | 2013-11-21 | 2015-05-21 | Labinal, Llc | Circuit breaker assembly including a plurality of controllable circuit breakers for local and/or remote control |
US10148071B2 (en) | 2014-01-03 | 2018-12-04 | Electronic Theatre Controls, Inc. | Breaker module with recessed breaker connections |
US9876334B2 (en) * | 2014-01-03 | 2018-01-23 | Electronic Theatre Controls, Inc. | Breaker assembly with mating platform and well connection |
US20170005458A1 (en) * | 2014-01-03 | 2017-01-05 | Electronic Theatre Controls Inc. | Electrical circuit breaker assembly |
US9531126B2 (en) | 2014-06-05 | 2016-12-27 | Chatsworth Products, Inc. | Electrical receptacle with locking feature |
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US9460881B1 (en) * | 2015-04-30 | 2016-10-04 | Eaton Corporation | Compact plug and socket unit isolator systems for motor control centers (MCC) and related MCC cabinets |
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US10102994B2 (en) | 2016-04-19 | 2018-10-16 | Safran Electrical & Power | Integral contact socket for plug-in circuit breakers |
US9984845B2 (en) * | 2016-05-11 | 2018-05-29 | Safran Electrical & Power | Circuit breaker with interference fit socket |
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